Senior Engineer - Process-Chemaid Lab​/QC Indirect

Position: Senior Engineer - Process-Chemaid Lab/QC Salaried Indirect
Location: Saddle Brook

Job Title:

Senior Process Engineer Functional Reporting:
Manager - Process Engineering Department:
Process Engineering
Summary
The Senior Process Engineer provides technical leadership for the development, scale-up, optimization, and continuous improvement of manufacturing and assembly processes for new and existing cosmetic products. This role serves as a subject matter expert for process design, technology transfer, equipment evaluation, and operational excellence initiatives. The Senior Process Engineer leads complex projects, mentors junior engineers, and collaborates cross-functionally to ensure safe, efficient, GMP-compliant, and cost-effective manufacturing operations while supporting business growth and innovation.

Essential Duties and Responsibilities

Lead technical evaluation of new product opportunities, customer requirements, and manufacturing feasibility assessments, including equipment capability, capacity analysis, process risk identification, and commercialization strategy.
Serve as the primary technical lead for new product introductions, ensuring successful implementation from development through commercial production.
Lead customer technical transfers, process validations, and scale-up activities, ensuring alignment between customer specifications and manufacturing capabilities.
Evaluate manufacturing processes and identify opportunities for process optimization, automation, productivity improvements, and cost reduction.
Partner with Process Engineering Manager and Engineering leadership to define capital expenditure (CAPEX) requirements, justify investments, and support equipment selection, installation, commissioning, and qualification activities.
Design, execute, and oversee pilot batches, process trials, and validation studies; analyze results and prepare technical reports with recommendations for implementation.
Provide technical leadership during process troubleshooting activities, utilizing root cause analysis and data-driven methodologies to resolve complex manufacturing challenges.
Lead continuous improvement initiatives focused on yield enhancement, waste reduction, cycle time improvement, labor efficiency, equipment reliability, and overall operational effectiveness.
Collaborate with Quality, Production, R&D, Supply Chain, and Engineering teams to ensure robust manufacturing processes and successful project execution.
Develop, review, and approve manufacturing, filling, and assembly specifications, procedures, and process documentation in compliance with cosmetic GMP requirements.
Support process validation protocols, change control activities, risk assessments, and investigations related to manufacturing processes.
Monitor process performance through data analysis, statistical tools, and key performance indicators (KPIs); recommend and implement corrective and preventive actions.
Assist in maintaining formula management systems, ERP/MES systems, and manufacturing master data to ensure process accuracy and consistency.
Mentor and provide technical guidance to Process Engineers, Engineering Technicians, and cross-functional team members.
Maintain advanced knowledge of batching, mixing, filling, packaging, and assembly technologies applicable to cosmetic and personal care manufacturing.
Support regulatory, customer, and internal audits as a technical representative for manufacturing processes.
Ensure compliance with all safety policies and actively promote a culture of safety and continuous improvement.
Perform other duties as assigned.

Knowledge, Skills, and Abilities

Bachelor's degree in chemical engineering, Mechanical Engineering, Industrial Engineering, Chemistry, or related technical field required.
Minimum seven (7) years of manufacturing engineering experience, preferably within cosmetic, personal care, pharmaceutical, food, or other GMP-regulated industries.
Minimum five (5) years of direct process engineering experience with demonstrated success leading technical projects and process improvement initiatives.
Strong knowledge of cosmetic Good Manufacturing Practices (GMPs); experience in regulated manufacturing environments required.
Proven experience with process scale-up, technology transfer, validation, and commercialization of new products.
Experience evaluating and implementing capital equipment projects and manufacturing technologies.
Advanced analytical, troubleshooting, and root cause analysis skills.
Strong understanding of manufacturing processes including mixing, filling, packaging, and assembly operations.

Experience with Lean Manufacturing, Six Sigma, statistical process control, or continuous improvement methodologies preferred.
Excellent project management, organizational, and leadership skills.
Ability to manage multiple complex projects and priorities simultaneously.
Strong written and verbal communication skills with the ability to present technical information to customers, leadership, and cross-functional teams.
Proficiency in Microsoft Office applications; experience with ERP, MES,…